Automated manufacturing architectural millwork

ABSTRACT

A system and method for making made-to-order architectural millwork of custom dimensions; including the design of wood joints and a system for deploying them within the overall structural design of individual architectural millwork units, as well as methods for online design and ordering, automated writing of machine code, robotic part preparation, and simplified on-site installation. With the automation and generation of digital code for manufacturing custom architectural components, this method makes the formation of distributed manufacturing centers possible. Through this method and with minimum re-tooling and/or training, these centers are able to produce custom millwork more efficiently and effectively than traditional custom millwork woodshops.

BACKGROUND

There are currently two basic market solutions for the production ofarchitectural millwork. These primarily include manufacturing units ofpre-determined sizes or the production of custom units with lessautomated methods. While the first method may be more affordable, therealities of construction often require, at a minimum, a combination ofboth methods when units of fixed dimensions do not fit within theoverall dimensions of the installation site, resulting in design andcoordination costs that are additional to the purchase and basicinstallation of the units themselves. Designing solutions for complexobject and space problems, such as the design and coordination of customarchitectural millwork in a space, may involve the use of drafting andmodeling software. Current software solutions may require considerabledrafting expertise and familiarity with the design problem. The time andskill required to generate initial valid solutions for considerationwith current technologies may be a significant barrier for access tocustom architectural millwork products. The design and production ofcustom units without automated methods may be less affordable thanautomated methods, but may be of a higher quality. Therefore, it wouldbe desirable to develop an automated design and manufacturing processfor creating high quality, made-to-order architectural millwork withcustomizable dimensions and reasonable costs.

SUMMARY

A system and method for making made-to-order architectural millwork ofcustom dimensions; including the design of wood joints and a system fordeploying them within the overall structural design of individualarchitectural millwork units, as well as methods for online design(including automated design aids) and ordering, automated writing ofmachine code, robotic part preparation, and simplified on-siteinstallation. With the automation and generation of digital code formanufacturing custom architectural components, this method makes theformation of distributed manufacturing centers possible. Through thismethod and with minimum re-tooling and/or training, these centers areable to produce custom millwork more efficiently and effectively thantraditional custom millwork woodshops.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of embodiments of the present invention will be apparent fromthe following detailed description of the exemplary embodiments thereof,which description should be considered in conjunction with theaccompanying drawings in which like numerals indicate like elements, inwhich:

FIG. 1 shows an exemplary diagram of process for making made-to-orderarchitectural millwork of custom dimensions.

FIG. 2 shows an exemplary embodiment of a unit in the process.

FIG. 3 shows an exemplary embodiment of a unit with shelf in theprocess.

FIG. 4 shows an exemplary embodiment of a set in the process.

FIG. 5 shows an exemplary embodiment of design aids in the process.

FIG. 6 shows exemplary edge types in the process.

FIG. 7 shows exemplary joint types in the process.

FIG. 8 shows an exemplary CNC Machine in the process.

FIG. 9 shows an exemplary unit assembly in the process.

FIG. 10 shows an exemplary installation in the process.

FIG. 11A shows an exemplary project and parameters of the process.

FIG. 11B shows an exemplary project and parameters of the process.

FIG. 12A shows an exemplary coded edge type of the process.

FIG. 12B shows an exemplary coded edge type of the process.

FIG. 12C shows an exemplary coded edge type of the process.

FIG. 13 shows an exemplary diagram of distributed manufacturing with theprocess.

FIG. 14 shows an exemplary joint type of the process.

FIG. 15 shows another exemplary joint type of the process.

FIG. 16 shows another exemplary joint type of the process.

FIG. 17 shows another exemplary joint type of the process.

FIG. 18 shows an exemplary machine code generation diagram in theprocess.

FIG. 19 shows an exemplary diagram for making preprogrammed parametricunits in the process.

FIG. 20 shows an exemplary parametric part CNC geometry computation inthe process.

FIG. 21 shows exemplary joints per edge relative to distances betweenpoint objects in the process.

FIG. 22 shows another exemplary joint type of the process.

FIG. 23 shows an exemplary panel with one edge type and two joint typesin the process.

FIG. 24 shows an exemplary interior design product in the process.

FIG. 25A shows an exemplary building system product.

FIG. 25B shows an exemplary building system product.

FIG. 25C shows an exemplary building system product.

FIG. 25D shows an exemplary building system product.

FIG. 25E shows an exemplary building system product.

FIG. 25F shows an exemplary building system product.

FIG. 25G shows an exemplary building system product.

FIG. 25H shows an exemplary building system product.

FIG. 25I shows an exemplary building system product.

FIG. 25J shows an exemplary building system product.

FIG. 25K shows an exemplary building system product.

FIG. 25L shows an exemplary building system product.

FIG. 25M shows an exemplary building system product.

FIG. 26 shows an exemplary embodiment of a joint type.

FIG. 27A shows an exemplary embodiment of a set with 2 layers.

FIG. 27B shows an exemplary embodiment of a set with 3 layers.

FIG. 27C shows an exemplary embodiment of a set with 4 layers.

FIG. 28 shows an exemplary embodiment of different sets.

FIG. 29 shows an exemplary embodiment of a set divided into maximum andminimum numbers of subsets.

FIG. 30 shows an exemplary embodiment of a set insertion function.

FIG. 31 shows an exemplary embodiment of a set deletion function.

FIG. 32 shows an exemplary embodiment of a set editing function.

FIG. 33 shows an exemplary embodiment of a set editing function.

FIG. 34 shows an exemplary embodiment of a set editing function.

FIG. 35 shows an exemplary embodiment of a set editing function.

FIG. 36 shows an exemplary embodiment of a set editing function.

FIG. 37 shows an exemplary embodiment of a set editing function.

FIG. 38 shows an exemplary embodiment of a set editing function.

FIG. 39 shows an exemplary embodiment of a set editing function.

FIG. 40 shows an exemplary embodiment of a set editing function.

FIG. 41 shows an exemplary embodiment of a set editing function.

FIG. 42 shows an exemplary embodiment of a set editing function.

FIG. 43 shows an exemplary embodiment of a set editing function.

FIG. 44 shows an exemplary embodiment of a layout of a room.

FIG. 45 shows an exemplary method for generating a layout of a room.

FIG. 46 shows an exemplary embodiment of pre-programmed layout types.

FIG. 47 shows an exemplary embodiment of a wall layout.

FIG. 48A shows an exemplary embodiment of a method for generating a walldesign layout.

FIG. 48B shows an exemplary embodiment of a method for generating a walldesign layout.

FIG. 49 shows an exemplary embodiment of a method for generating a set.

FIG. 50 shows an exemplary embodiment of a method for generating a walldesign layout.

FIG. 51 shows an exemplary embodiment of a method for automaticallygenerating set designs.

FIG. 52 shows an exemplary embodiment of different sets with individualfitness scores.

FIG. 53A shows an exemplary embodiment of a set generator function.

FIG. 53B shows an exemplary embodiment of a set generator function.

FIG. 54 shows an exemplary embodiment of an input and an output of a setediting function.

FIG. 55 shows an exemplary embodiment of a method for solving a designproblem.

DETAILED DESCRIPTION

Aspects of the invention are disclosed in the following description andrelated drawings directed to specific embodiments of the invention.Alternate embodiments may be devised without departing from the spiritor the scope of the invention. Additionally, well-known elements ofexemplary embodiments of the invention will not be described in detailor will be omitted so as not to obscure the relevant details of theinvention. Further, to facilitate an understanding of the descriptiondiscussion of several terms used herein follows.

As used herein, the word “exemplary” means “serving as an example,instance or illustration.” The embodiments described herein are notlimiting, but rather are exemplary only. It should be understood thatthe described embodiments are not necessarily to be construed aspreferred or advantageous over other embodiments. Moreover, the terms“embodiments of the invention”, “embodiments” or “invention” do notrequire that all embodiments of the invention include the discussedfeature, advantage or mode of operation.

Further, many embodiments are described in terms of sequences of actionsto be performed by, for example, elements of a computing device. It willbe recognized that various actions described herein can be performed byspecific circuits (e.g., application specific integrated circuits(ASICs)), by program instructions being executed by one or moreprocessors, or by a combination of both. Additionally, these sequencesof actions described herein can be considered to be embodied entirelywithin any form of computer readable storage medium having storedtherein a corresponding set of computer instructions that upon executionwould cause an associated processor to perform the functionalitydescribed herein. Thus, the various aspects of the invention may beembodied in a number of different forms, all of which have beencontemplated to be within the scope of the claimed subject matter. Inaddition, for each of the embodiments described herein, thecorresponding form of any such embodiments may be described herein as,for example, “logic configured to” perform the described action.

According to an exemplary embodiment, and referring to the Figuresgenerally, a system and a method of an automated manufacturingarchitectural millwork may be described. According to an exemplaryembodiment, such a system and method may produce higher qualityarchitectural millwork with greater storage space and custom dimensionsat a competitive price. Increased structural integrity of the productmay be achieved with the design of wood joints and a system fordeploying them within architectural millwork units. Millwork units withcustom dimensions may be efficiently created through the process ofautomatically computing machine code for robotic part preparation. As aresult, custom architectural products may be produced with efficienciessimilar to mass production of units of standard shapes and sizes. Themanufacturing may be distributed into a network of regional centers(potentially in coordination or in partnership with existing third-partyshops); realizing efficiencies in transportation costs and allowing thecompany to scale and adapt to changes in market demand more easily thancentralized manufacturing centers. Also, the ability to fully automatecustom part fabrication from custom design parameters, may creategreater efficiencies through the creation and practical application ofautomated online customer-driven design tools.

According to an exemplary embodiment, a manufacturing process may beautomated creating high quality, made-to-order architectural millworkwith customizable dimensions. Such a process may be applicable tomillwork constructions including but not limited to cabinets, shelves,free-standing closets, credenzas, storage boxes, and vanities asdesired. In comparison to conventional industry mass production methods,the automated manufacturing process may have a number of benefits. Forexample, it may eliminate manual cutting and measuring during thecreation of dimensionally variable millwork and it may enable theintegration of efficient customer-driven design and installationtechniques.

In addition, the product may have structural benefits in comparison toconventional solutions. Reproducing proposed designs for connectingparts may be time consuming, require highly-skilled carpentry and may becost prohibitive with conventional made-to-order methods. The design ofthese connections as well as the methods for integrating them into amass production process with machine precision may provide for a productof greater strength (more durable) while using less material (morestorage space).

Turning now to exemplary FIGS. 1, 2, 3, 4 and 5 , FIG. 1 may show anexemplary diagram of a process 100 for making made-to-orderarchitectural millwork of custom dimensions. According to an exemplaryembodiment, the process may include five major phases: design 110,review 120, ordering 130, manufacturing 140 and installation 160. In anexemplary embodiment, the development of a millwork product may begin asa customer-initiated project and ends with the delivery of a coordinatedset of custom millwork units for installation. Also, in an exemplaryembodiment, the process may provide a web-based interface, and it mayallow the customer to drive the design process, and software maygenerate data and documentation for ordering, manufacturing, shippingand installing the millwork product. Such a process may provideopportunities to reduce overall labor, time, error and costs incomparison to conventional practice.

The process 100 may start with an option to either begin the designphase 110 or repair interface 102. The design interface 112 may presentan intuitive user interface. The user may then design the project 114using the user interface which may supply the user with design aids. Ina next exemplary step, the user may enter project parameters 116 (seeFIG. 11 for an example of project parameters), such as desireddimensions.

Next, the review phase 120 may begin. In a first exemplary step of thereview phase 120, the software may model the user's project 122. Then,the project may be viewed 124. The customer may view the project as aweb-based 2D and/or 3D representation. Further embodiments may allow thecustomer to view virtual reality and augmented reality formats. Somecustomers may be wary of how a piece of furniture looks on the internetand may instead seek to view the product in person. Virtual reality andaugmented reality may allow a customer to view the project as if it isin their room or right in front of them. The customer may view theproject in its entirety, including all sets and units, as well as eachunit individually within one frame. By isolating the sets or units, thesoftware may facilitate the use of design aids for adjusting parameterssuch as dimensions and alignments. The customer may then download thecustom digital models of the project as computer-aided design (CAD)files in 2D and 3D formats. This may facilitate the coordination oflarger projects which the units or sets may be integrated with. In afurther exemplary embodiment, scaled 3D models may be downloaded in aformat for 3D printing. In another exemplary step of the review phase120, the customer may view project data 126. Project data may includeinformation for final review and approval before ordering, such asdescriptions of each unit and project costs.

In a next exemplary phase, the product may be ordered 132 to begin theordering phase 130. Once the customer places an order 132, the softwaremay process the order 134. In processing the order 134, the software maysave the order to an online account and may also generate assembly data,installation data, order shipping data, order tracking data, drawings,models, and instructions for reference to facilitate with the assembly156 and installation 160.

After the ordering phase 132 has been completed, the manufacturing phase140 may begin. In a first exemplary step of the manufacturing phase 140,the manufacturing data may be computed 142. The manufacturing data maybe further illustrated in FIG. 18 . The manufacturing data may producethe material list 144, generate the machine code for directing thecutting, routing, etching, milling, sawing, bending, forming, welding,pinning, gluing, taping, sanding, painting, finishing, holding,conveying, picking and/or placing machine operations (such as for a CNCmachine) 146, may provide assembly data 148, and may provide data tofacilitate the installation process. Exemplary assembly data may includedata for tracking parts, orienting parts, assembling parts in order,picking parts, holding parts, conveying parts, joining parts, catalogingunit hardware, identifying unit hardware locations, installing unithardware, picking units, holding units, conveying units, finishingunits, packaging units, and cataloging unit adjacencies. Examples ofdata used to facilitate the installation process may include data foridentifying unit locations within an overall designed space (such as akitchen where the physical units are compared to visualizations of unitsof automatically generated physical drawings or automatically generateddrawings and models visualized on a personal computer or augment realitydevice), identifying peripherals of a unit that may require separatepackaging and on-site assembly, and providing on-site installationinstructions (such as unit installation sequence). The assembly data maybe delivered to the manufacturing center through various methods asstatic or interactive text, drawings and modeled illustrations.

Exemplary visualization formats may include automatically generatedlabels for part identification, orientation, assembly order, and partadjacency indices. These labels may be automatically printed andtemporarily adhered to parts manually or automatically with a roboticapparatus. More complex data and instructions may be delivered to themanufacturing center as programs for augmented reality devices or anyother type of graphical user interface. Augmented reality models (ormodels viewed on other computing devices such as a personal computer ormobile device) and visualizations may provide access to assembly data,and may provide the manufacturer with the information needed to completethe task within a single program designed for the assembly of a unit orunits. This may allow the company to create programs that automaticallydesign and deliver a model for a custom unit to the manufacturerirrespective of the manufacturer's level of experience assembling likeunits. Some manufacturers may use the model to access a limited amountof information, while other manufacturers may use the same model toaccess more information, thus increasing their confidence in the ways inwhich they are assembling the units. The training manual for all levelsof experience may be imbedded in the assembly data for any given unit.This may minimize errors in the assembly process as new manufacturesbecome familiar with the manufacturing process.

Assembly data may also be delivered electronically to programmableapparatuses at the manufacturing center to assist in the shaping,assembly, convey, sorting, and shipping of parts and units, such ascarts with electronic displays. Identifying, sorting, and tracking partsmay be a considerable challenge with custom units, where every part of aproject order is unique. Programs may be created for the carts, wherethe display panels may be associated with slots or containers of thecarts, and may indicate locations for placing parts with uniqueidentification markings corresponding to markings on the display panelsof the carts. When parts are removed from the holding apparatus of a CNCmachine or assembly station, they may be quickly placed in containers orslots of the carts. The program may direct the positions of each part inthe cart so that they may be quickly and sequentially picked from thecart to be placed in another CNC machine holding apparatus or assembledin order. For example, a cart may contain parts for two units of aproject.

The parts in the cart could be arranged so that the manufacturer mayquickly pick from the cart parts for the first unit in the order bywhich they are assembled, followed by parts of the second unit in theorder by which they are assembled. The cart can then be re-programmedfor parts of other units or for sorting and delivering assembled unitsto another manufacturing station, such as a finishing station. Thesoftware may then use the material list to order the material for theproject 150, as previously calculated 142. An example of material usedin the process is stock material pre-processed to industry standardsizes, such as sheets of wood, boards of wood, sheets of foam, sheets ofmetal, sheets of plastic, sheets of glass, pipes, tubes, and other metaland plastic extrusions.

In a next step, the material may be delivered from the supplier to theshaping location 152. At the shaping location, the material may beshaped 154, for example, using a CNC machine or by other means. Examplesof part shaping may include cutting, routing, milling, forming, bending,and sawing. After shaping, the shaped material may then be assembled156. The shaped material may then be finished 158, such as by sanding,staining, and painting the assembled units. The material may be finishedbefore shaping, after shaping, or not finished at all.

The final phase may be the installation phase 160. The product may beshipped from the cutting and assembly location to the install location162. Alternatively, the product may be stored at a regionalmanufacturing center or at another storage center for convenientpick-up. In a final step, the customer may install the units 164.

Referring now to FIGS. 2, 3, 4 and 5 , FIG. 2 may show an exemplaryembodiment of a unit in the design process. The ‘w’, ‘d’, and ‘h’denoted in FIG. 2 may represent the width, depth, and height of thedesired object. A customer may enter parameters to specify the width,depth, and height, or a set of recommended specifications may be used.In exemplary FIG. 3 , an exemplary embodiment of a unit with a shelfselected in the design process may be shown. In addition to the globalparameters shown in FIG. 2 , each unit may have internal parameters foradding shelves, drawers, doors, etc. Referring now to FIG. 3 , the shelfmay be selected, moved, or removed. Further, the shelf may be copied,and an additional identical shelf may be placed on the design. FIG. 4may show an exemplary embodiment of a set in the design process. The setin FIG. 4 may be aligned such that they are of equal heights and depths.If the units are configured to be combined as an interconnected set, theinterior walls 202 may be unfinished and may be fitted with a joint orother means for connecting the two walls.

According to an exemplary embodiment, the process may begin with thedesign phase, which may include customer-driven design usingpre-programmed elements. In an exemplary embodiment, the customer mayinitiate a project which is defined as unit(s) and/or set(s) of units(shown in FIG. 11A) rendered in a web based three-dimensional graphicaluser interface. FIG. 5 may show an exemplary embodiment of design aidsin the design process. Each unit may be added to a web basedthree-dimensional model at a default set-out position, a customerdefined set of coordinates (x, y, z) relative to an origin or objectalready positioned in the model, or by associating one side of the addedunit to a selected side of a unit already positioned in the model,forming a set as shown in FIG. 4 and FIG. 5 . According to an exemplaryembodiment, the forming of sets may allow the software to catalogadjoining units. There is no limit to how many adjoining units exist ina single set. This information may be used to generate customdocumentation and connections that simplify the installation process.

According to an exemplary embodiment, other design aid features of thegraphical user interface may include functions for aligning and settingunits of equal sizes as shown in FIG. 5 . In an exemplary embodiment,the aligning function may facilitate the alignment of two or more sideswith parallel planes by identifying a target plane. For each manipulatedunit, the function may compute a value that either increases ordecreases its overall dimension that is perpendicular to the targetplane. Also, in an exemplary embodiment, another function may re-computevector parameters of equal value for selected units, such that thedirections of the parameters are parallel, and their sum value is clientdefined.

According to an exemplary embodiment, at the conclusion of the designphase, the review phase may begin. The system may compute and rendertwo-dimensional and three-dimensional computer-generated visualizations,a list of project parameters (such as types of units, dimensions,numbers of doors/drawers/shelves), and the project cost. Optionally, thecustomer may download these representations as files readable bycomputer aided design software for integration into the design of largerprojects requiring greater coordination. The parameters of projects maybe saved as closed proprietary specifications for builders. If thecustomer accepts, the order processing phase may begin. In an exemplaryembodiment, order processing may be executed by software that takes thedesign parameters for each unit as inputs and outputs lists of machineinstructions for the automated cutting of parts in preparation for themanufacturing phase. The machine instructions may include details suchas the height and width of each piece, the number of pieces, and theshapes of each piece. The pieces may be cut into rectangular shapes. Theedges of the pieces may be cut to form a protuberance or aperture tojoin such that the edge of one piece may join with the edge of another.

Referring now to exemplary FIGS. 6 and 7 , different exemplary jointtypes and edges may be shown. Each unit may be a programmed set ofsurfaces and edge types. As shown FIGS. 6 and 7 , each edge type may bea set of joints. Any type of joint or combination of types of joints maybe contemplated. FIG. 6 may illustrate the application of various jointsmortise and hammer-headed tenon joints 602, mortise and tenon joints604, splice joints 606, and mechanical fasteners 608. One or moremortise and hammer-headed tenon joints 602 may be used to join the edgesor corners of two pieces at a 90° angle. One or more mortise and tenonjoints 604 may join the edge or corner of one piece to an interiorportion of another piece. One or more splice joints 606 may join thecorner or edge of one piece to the corner or edge of another piece suchthat the two pieces run along the same plane to form one flat piece.Additionally, one or more of mechanical fasteners may join two pieceswhich may be stacked on top of or next to each other such that theirsurfaces are parallel and connected.

FIG. 7 may show various methods for joining two planar parts of wood. Aninety-degree corner 702 may be formed using a process similar todovetail joinery where the edges of the two parts interlock. A T-shapedconnection where the edge of one piece connects with a center orinterior portion of another piece 704 may be formed by creating anaperture in the interior portion of one piece and a correspondinglysized protuberance on the edge of another piece. Further, a splice joint706 may connect two planar parts of wood of different thicknesses suchthat they run along the same plane in the same direction, with one pieceextending out from the end of the other piece. Additionally, FIG. 7 mayalso show a method of joining two planar and parallel pieces where onepart may have an embedded insert nut 708 and may connect to another partwhich has a screw 710 which engages the nut 708. Various other types ofjoints may be implemented into the pieces, such as dovetail or tongueand groove joints.

The number of joints and the spacing between each joint (shown in FIG.21 ) may be formulaically calculated from parameters defined in thedesign phase. Software may compute machine code for all joints and partsrequired to construct each unit from flat sheets and/or boards ofnon-metal material (such as plywood and solid hardwood). Parts may bealgorithmically arranged in a two-dimensional plane with x and y lengthsequivalent to sizes of physical material to be machine cut (Thisfunction may be called nesting). Software may then output machinereadable digital files for a computer numerical control (CNC) routingmachine, as shown in FIG. 8 .

Referring now to exemplary FIG. 8 , a CNC routing machine may be shown.The CNC machine may have a router 802 which may be the main cuttingelement. The router 802 may spin and may be fitted with a cuttingsurface. The router 802 may be connected to a number of rails which mayallow the router to move anywhere along the flat bed 804 of the CNCmachine. A sheet of material to cut 806 may be placed on top of the flatbed 804, such that the router may cut any part of the material 806.Multiple parts 807 may be cut from a single sheet of material 806. Afixed x-axis rail 808 may be affixed to a side of the CNC machine. Ay-axis rail 810 may be perpendicularly connected to the x-axis rail 808,allowing the y-axis rail 810 to move along the x-axis rail 808. A z-axisarmature 812 may be movable connected to the y-axis rail 810, such thatthe z-axis armature 812 can slide in any direction along the y-axis rail810. Since the y-axis rail 810 can additionally slide along the x-axisrail 808, the z-axis armature 812 may be moved to anyplace along theplane of the flat bed of CNC machine, in the x and y direction. Further,the z-axis armature 812 may move in a vertical direction, down towardsthe flatbed 804 and material to be cut 806. In this example, theapparatus for holding the material may be a flat vacuum table 804.Examples of other CNC machines include machines that have an apparatusfor holding material and numerically controlling the motion of a toolfor shaping parts, including subtractive and additive manufacturing toolheads, of various material types, such as the parts shown in FIG. 25 .The material holding apparatus may also be numerically controlled, andcapable of moving the held material in the x-axis, y-axis, z-axis, orany combination of the three, while handling or shaping material.

After cutting, the parts may be unloaded from the machine bed andassembled. Each part may have an identification tag indicating the unittype and its place within the assembly sequence as shown in FIG. 9 .Adjoining parts may be held together with glue and friction. Lack ofrigidity is a common critique of manufactured millwork. This istypically overcome through the use of heavier duty mechanical fastenersand thicker, higher quality materials. The interlocking joinery of theproposed method may yield superior rigidity with material of minimalthicknesses, reducing potential time lost in sending back damaged unitswhile increasing the storage area available to the client. Parts may beassembled with a single tool, such as a mallet and a simple technique,such as hammering. Because the complex cutting may be computed by thesoftware and performed by the CNC machine, fewer labor skills arerequired to assemble custom sized millwork of superior quality andrigidity.

Referring now to exemplary FIG. 10 and FIG. 11 , the assembly of a setmay be shown. As shown in FIG. 10 , a set 1000 may be a combination of aplurality of products. (For example, a given set 1000 may include a unit1002 having a door which itself constitutes a unit 1004, or may includea cabinet which operates as a unit 1002 defined within another unit1004, such as a row or column of cabinets.) Unit 1002 and unit 1004 maybe similarly sized in the design phase such that they may be placed nextto each other as a single unit. Mechanical fasteners may be used to jointhe first unit 1002 and the second unit 1004. As shown in FIG. 10 andFIG. 7 , the mechanical fasteners may be a screw 710 in a first unit1002 which engages a correspondingly placed nut 708 in the second unit1004. Multiple mechanical fasteners may be used, depending on the sizeor structure of the units. In an exemplary embodiment, the first unit1002 and the second unit 1004 may have equal heights and depths.

FIG. 11A may show an exemplary embodiment of wall mounted cabinets 1100.The cabinets may be a combination of multiple units. In this exemplaryembodiment, a double cabinet 1102 is joined with a single cabinet 1104.They may be joined by an adhesive, screws and nuts, or by any othertechnique. Further, a leveling platform 1106 may be placed under thejoined units 1102 and 1104. The leveling platform 1106 may be fixedlyattached to the units and may also be fixed to a wall.

FIG. 11B may be an exemplary embodiment of unit parameters related tothe exemplary cabinet unit in FIG. 11A. The design software may recordthese parameters according to a user's specifications, or some of themmay be automatically populated by the software. Possible parameters thatmay be recorded include the type of unit, width, height, depth, numberof peripherals, and adjacencies. The type of unit may be a specificstyle or may refer to the position or place it is to be mounted. Thenumber of peripherals may include doors, shelves, windows, or otherfixtures that may be mounted or attached to the furniture. Further, thewidth, depth, and/or height of each peripheral may be included. Theadjacencies parameter may include information about which units may bedirectly adjacent or attached to the unit being described.

For example, in FIG. 11A the double cabinet 1102 is adjacent andattached to the cabinet 1104, so an exemplary adjacency parameter forcabinet 1102 may contain information defining the side which cabinet1104 is attached to, such as the left side, and the method ofattachment, which in this exemplary case may be screws and nuts. Anotheradjacency parameter for cabinet 1102 may define the leveling platform1106 on the bottom of cabinet 1102 and may implement a screw/nut methodof attachment. In another exemplary embodiment, the method of attachmentmay be an adhesive, or any other attachment method such as may bedesired. Further, the adjacency information may be stored or viewed inthe form of an adjacency graph 1110. The adjacency graph 1110 may showwhich items are attached to one another as well as the location of theirattachment. Additionally, the adjacency graph 1110 may store edge typeinformation.

In an exemplary embodiment, edge type information may be stored in a 3Dmodel of the unit, with the edges denoted by an edge type symbol, asshown in exemplary FIG. 12A. In exemplary FIG. 12A, an edge may bedenoted by an ‘e’, and the type of edge may be denoted by the subscriptunder the e. For example, e_(2B) may represent a mortise shaped edgethat may be configured to join a corresponding tenon shaped edgerepresented as e_(2A). In this exemplary embodiment, the edges mayinstead be represented by actual drawings of the contemplated edges, asshown in FIG. 12B. The assembled unit 1200 may be a 3-dimensional modelwhich illustrates all the edges and the corresponding joints created.

Referring now to exemplary FIG. 12C, an illustration of the edge typesof a unit may be shown. The software may automatically compute thelocation and type of edges for each piece. The edge information may thenbe saved in a format that is readable by a CNC machine. The CNC machinemay then cut and drill the parts. As a result, the amount of manuallabor, such as cutting, drilling, or measuring the parts, may bereduced. Additionally, the edge profile of certain parts, such as thehorizontal piece 1202 in FIG. 12C, may follow the inside surface of door1204, and may run along a portion of door 1204 which is made thinner inorder to receive the horizontal piece 1202, thus maximizing storagespace. In addition to structural rigidity, the edge detail may producean inlay appearance, such as when two edges are composed of differentmaterials.

The automation of manufacturing data (CNC machine code, assemblyinstructions, and associated project metadata) from customer definedparameters for custom millwork may enable the practical implementationof a distributed manufacturing network shown in FIG. 13 . The customers1302 may place orders by utilizing the design interface 1304. The designinterface 1304, as previously discussed, may receive customer input andthen may compute manufacturing data 1306. The manufacturing data 1306may be in the form of code readable by a CNC machine. The data 1306 maythen be sent to a manufacturing center 1308. Additionally, the softwaremay also order materials needed or send a list to the manufacturingcenter specifying the materials needed. Alternatively, the software maysend bills of materials to centers. In another exemplary embodiment, thematerials may be cut at one manufacturing center 1308 and then sent asflat-packed parts to centers closer to the customer for assembly andfinishing. The manufacturing center 1308 may be chosen based on thecustomer's location.

By selecting manufacturing centers 1308 located close to the customers1302 placing orders, there may be reductions in transportation andenergy costs and representatives from these centers may more easilysupply on-site assistance with the pre-order and post-delivery phases.Additionally, the business may be able to develop contracts withexisting regional shops already in possession of the skilled laborand/or machinery required for executing the orders. Alternatively, thecompany may contract the assembly with a third-party shop and supply theshop with flat-packed parts from a separate robotic cutting facility orfacilities. With minimum re-tooling and/or training in the manufacturingmethodology and techniques, these shops may gain access to a largermarket for custom millwork and may complete the work without thechallenges associated with drafting, measuring, cutting custom parts, ordescribing design limitations to customers. In return, the business maygain rapid scalability and resilience to changes in market demand. Thecompany may be able to develop units and sets of other types ofarchitectural products of various materials, by designing newpre-programmed units and engaging shops with other types of CNCequipment such as programmable laser-cutters, water-jet cutters, andfive axis machines with custom tool heads.

A customer 1302 may also select a preferred regional manufacturingcenter 1308 if desired. Representatives from a manufacturing center 1308may be available to provide services such as direct assistance duringthe design or installation phase. For example, a representative from themanufacturing center may provide a local installation team that caninstall the units, or the center itself may employ one or morespecialists who can install the units or sets. The representatives mayassist customers with on-site measurements, design selection, andconfigurations. Further, the manufacturing center 1308 may have displaymodels of already manufactured units or sets that a customer may chooseto see prior to purchasing or designing their own unit.

The project may be shipped to the customer as ordered set(s) of unitsfor the installation phase. Unit identification tags correspond to theunits shown in the project web-based design model and the installer mayrefer to this model as an installation aid. With the pre-fabricatedthreaded inserts and pre-drilled holes for machine screws, for example,as shown in FIG. 6 , “e4”, the installer may rapidly and accuratelyalign units within set(s) as shown in FIG. 10 . It is relatively timeconsuming to utilize these types of fasteners with conventional custommillwork methods and it is impractical with standard manufactured unitsthat are designed and built with no reference to specific adjoiningunits. On the other hand, in exemplary embodiment, the ability of thesoftware may map the adjacencies within a set of units and translatethat information into machine code that accurately positions thefasteners enabling the effective use of this fastener

Also, in exemplary embodiment, project data may be saved in an onlineaccount for reordering parts for repairs. A mechanical fastenersolution, for example, as shown in FIG. 7 “j4” may facilitate easyreplacement of new parts without residual damage to adjoining parts fromthe use of typical on-site unit alignment solutions (ex-nails and woodscrews).

Referring now to the exemplary embodiment in FIG. 14 , a mortise andhammer-headed tenon joint may be shown. This type of joint may beimplemented when two pieces are connected at a 90° angle. The letters onpart A of FIG. 14 correspond with the letters on part B of FIG. 14 ,such that the same letter indicates the same length on both parts. Thehammer-headed tenon 1400 may be shown on part A as a tenon with a neck1402 and a thicker head 1404. The head 1404 may be sized such that itmay be received by the upper portion 1414 of the notch 1410. The lowerportion 1412 of notch 1410 may be thicker than the upper portion 1414such that it may contact the neck 1402 of the tenon. Note that in thisexemplary embodiment, the tenon 1400 is configured such that it must bevertically connected to a horizontal mortise 1410, however otherconfigurations are contemplated.

Referring now to the exemplary embodiment of a joint in FIG. 15 , amortise and tenon joint may be shown. A rectangular tenon 1502 on afirst part 1500 may be sized such that it may enter a rectangularaperture or mortise 1504 in a second part 1510. The advantage to themortise and tenon configuration is that the mortise may be placedanywhere along the second part, such as in a middle portion. A mortiseand tenon joint may be used to affix shelves, walls, or any otherfixtures to a unit.

Referring now to the exemplary embodiment of a joint in FIG. 16 , asplice joint may be shown. A small rectangular mortise 1602 on a firstpart 1600 may receive a correspondingly sized tenon 1612 on a secondpart 1610. Additionally, a hammer headed tenon 1604 on the first part1600 may contact a correspondingly shaped mortise 1614 on the secondpart 1610. Further, a groove 1606 on the first part 1600 may receive abump 1616 on the second part 1610. The two parts may be joined such thatthey run along the same plane and extend from one another. By applyingmultiple types of connections, such as a hammer-headed tenon, a groove,and a rectangular tenon, the joint may be more stable than traditionaljoints that only use one type of connection.

Referring now to exemplary FIG. 17 , mechanical fasteners may be shown.A threaded insert nut 1702 may be installed in a first part. The nut maybe inserted into a CNC drilled hole 1704. The second part may contain acorrespondingly placed CNC drilled hole 1706. A screw may be insertedinto and through the hole 1706 in the second part until the screwcontacts and threads with the nut 1702 placed in the hole 1704.

Referring now to exemplary FIG. 18 , a machine code generation diagrammay be shown. The process for generating the CNC machine code beginswith the default unit parameters 1802. The customer may choose a unit,and the software may provide sample unit parameters 1802. The customermay then assign parameters to the unit 1804 as desired. Once theparameters are finalized, the software may define a unit object 1806,which may be a single unit or product. An object as described in thissection may be a 2D or 3D computer aided design object. In a next step,the unit object may be further analyzed to create or compute one or morepart objects 1808. The part objects may correspond to the differentpieces of the unit, such as the walls, panels, or shelves. When the partobjects are computed 1808, each part's CNC geometry 1810 may beproduced, including their edges and sizes. FIG. 20 may further describethe computation of CNC geometry. In a next step, the software may applya nesting algorithm 1812 to nest the part CNC objects, producing anested CNC geometry 1814. The nesting algorithm may optimize the CNCgeometry such that a minimal amount of material is wasted when the partsare cut from sheets. The nested CNC geometry may then be written orsaved as a CNC file 1816. The CNC file is then sent to a desiredmanufacturer 1818. The manufacturer may place a material, such as a woodsheet, on a CNC bed 1820. Finally, the CNC file previously written isrun on the CNC machine 1822, cutting the wood sheet as calculated andmodeled by the part object geometry.

Referring now to exemplary FIG. 19 , FIG. 19 may illustrate how a unitobject is computed. First, the user (such as a customer or company) maydesign or sketch a new unit 1902 through a design interface. The designinterface may present an intuitive interface and may be web-based. In anext step, the software may determine the type of edges to be used 1904as well as which objects contain edges 1906. The software may determinethe lengths of the edges of each part (as determined from the unitparameters such as the height, depth, and width) 1908. The lengths andorientations of the edges of each part may be stored as vectors 1910.The vectors may then be used to model parametric points of two or threedimensions 1912 in order to generate toolpath data for each part forshaping (cutting, etching, routing, milling, sawing, bending or forming)with a CNC machine. The data from the vectors, point objects, unitparameters, edge types, and edge objects may be compiled in order tocompute a single unit object 1914. The unit parameters may be defined asvalue ranges rather than discrete values, and the unit object may bestored in computer memory to generate multiple custom units of a similartype with minimal inputs (simply declaring unit parameters withpre-programmed value ranges).

Referring now to exemplary FIG. 20 , FIG. 20 may illustrate the sequenceof CNC geometry computations, as explained in FIG. 19 . V₁₋₃ mayillustrate vectors that represent the length and orientation of a singleedge of a part. P₁₋₆ may be different point objects which may define thestart points, end points, and adjacencies of the edges. For example, thefirst edge with start point P₁ and end point P₃ may be adjacent to thesecond edge with start point P₃ and end point P₄ (the end point of thefirst edge is the same as the start point of the second edge). Thecoordinates of points P₂₋₆ are calculated from an origin point P₁ afterthe part parameters are defined. In this example the length of V₃ may beequal to the width of a unit, while the length of V₁ may be equal to theheight of a unit. From a catalog of edge types with their own sets ofvectors, points, edges, and joint types, toolpath data for the part maybe generated and compiled into a CNC file. The CNC machine may thenshape the desired edges and joints according to the given CNC file.

Referring now to exemplary FIG. 21 , the number of joints per edgerelative to distances between point objects may be shown. A longer edge2102 may have more joints per edge than a shorter edge 2104. Thesoftware may compute the number of joints per edge based on the distancebetween point objects.

Referring now to exemplary FIG. 22 , FIG. 23 , and FIG. 24 , a cornerjoint type may be shown. A slanted mortise 2202 on object 2200 mayreceive a slanted tenon 2212 on object 2210. FIG. 23 and FIG. 24 mayshow an example panel with the corner joint. The corner joint may beimplemented in a unit with any number of sides and variable anglesbetween adjoining sides, as shown in FIG. 24 . Using the same processpreviously described and outlined in FIG. 1 , a picture frame such asthe ones shown in FIG. 24 may be created. The customer may choose anydesired number of sides, shapes, or sizes for the picture frame.Additionally, the CNC technology may enable the integration of customengravings into the face of the frame material.

With the processes outline in FIGS. 1, 18, and 19 , a customer may use aweb-based user-interface to design digital surfaces by positioning pointobjects and declaring edge objects in a 3D graphical user interface. Thecustomer may use functions of the interface for joining surfaces as oneor more sets. The software may compute the intersection of thesesurfaces and render the result in the 3D graphical user interface. Othercustomer input parameters may include building system types. Theseinputs may be referred to as design inputs. Various design inputs mayallow the software to compute manufacturing data from pre-programmed andparametric unit objects. Unit objects may include structural units, suchas in FIG. 25B, sheathing units such as in FIG. 25H, and formwork unitsas in FIG. 25I. An advantage of these processes and pre-programmed unitsmay be shown in FIG. 25 . These processes and pre-programmed units allowa customer to construct complex geometric architectural form whileminimizing the amount of manual measuring, cutting, or assemblingnecessary, thus reducing the time and labor necessary to complete such atask.

The term “set of structural units” may refer to an ordered set ofstructural units. For example, FIG. 25B may show a set of structuralunits. The structural units in this figure form a complex doubly curvedsurface. The surface may have u- and v-coordinates that correspond to x-and y-coordinates of a flattened design surface. The flattened designsurface may be a network of sets, like the network of sets illustratedin FIG. 27 . For instance, a low level set within the network may be thecombination of regions e1 and e2 in FIG. 25B, where the combination ofthese regions has a width and a height parameter. Similarly, regions c1and c2 may represent a set, and regions a1 and a2 may represent anotherset in FIG. 25B. These three sets may be grouped in another set to forma column. Prior to generating CNC manufacturing data for the units, unitand part edge point locations as well as vector lengths and orientationsmay be calculated by mapping these coordinates from the x- andy-coordinate system of the flattened design surface to the u- andv-coordinate system of the three-dimensional design surface. FIG. 25Cmay show a single structural unit. The structural unit in exemplary FIG.25C may be a set of assembled parts. In this exemplary case, the unit isa triangle formed from round tube, flat plates and mechanical fasteners.An alternative to the mechanical fasteners may be welded connectionsperformed by a CNC welding machine. A structural unit may be composed ofvarious materials, such as round tubes or flat plates which may be cutfrom stock material using a CNC machine. FIG. 25D may show a sectionthrough corner connection of a structural unit. FIG. 25E may show theconnection between two structural units, creating a set. FIG. 25F mayshow a cross-section of a connection of two structural units. The anglebetween the two units may vary and may be calculated from customerdefined inputs. FIG. 25G may show the connections between a set ofstructural units and other building components.

Exemplary FIG. 25H may show a set of sheathing units. A sheathing unitmay be sheet material that may be formed from a doubly-curved surface,and may consist of an ordered set of parts with shapes, sizes, andmanufacturing data computed from design inputs by software.Manufacturing data may include cuts, holes, and markings on the parts aswell as locations to connect a sheathing unit to other parts, units, orbuilding components. Parts of a sheathing unit may be cut with a CNCmachine.

Exemplary FIG. 25I, FIG. 25J, FIG. 25K may show sets of formwork units.A formwork unit may be a part cut by a CNC machine from a thick sheet,such as rigid foam, or a thick sheet of a composite of laminatedmaterials. One side of a formwork unit part may be cut with a CNCmachine such that the cut surface may be parallel to one surface of amasonry wall, and where each masonry unit may be positioned at varyingangles relative to adjacent masonry units. Reference graphical markingson the formwork unit may be used as guides for locating masonry units ofstandard sizes and may be used to communicate dimensional data forcutting of masonry units or may be used for calibrating the position ofa robotic masonry laying machine in the physical 3D environment. Thismay reduce accrued error and conflicts from discrepancies between thedesigned virtual model of the wall elements and adjustments required tomeet other physical architectural building components of otherconstruction methods with varying degrees of accuracy. Similar to thestructural units shown in FIG. 25B, the rigid foam unit shown in FIG.25J may be designed as a low level set within a network of sets, such asthe full assembly of rigid foam units shown in FIG. 25K. In addition tothe perimeter compound saw cuts, each course with markings for bricks asjoint types may be an edge type used in the design of the unit modeledwith software. Angles for the compound CNC saw cuts, and routing depthsof the CNC milling machine shaping the rigid foam unit may be calculatedafter mapping the x- and y-coordinates of the unit object in theflattened design surface to the u- and v-coordinates of thethree-dimensional design surface. Parts of a foam unit may be gluedtogether with a CNC gluing machine.

FIG. 25L may show a cross-section of the assembly of a building system.The building system may be a combination of sets of units definedthrough design inputs. A building system may contain a set of structuralunits connected to one or more sets of structural units, sheathingunits, and/or formwork units.

Referring now to exemplary FIG. 25M, FIG. 25M may illustrate theconnection detail between non-parallel building components. A round tubeof a structural unit may be connected to a second part, such as asheathing unit, a formwork unit, or any building component. The normalsurface vector at the point of connection with the second part may notbe perpendicular to the center axis of the round tube.

Referring now to exemplary FIG. 26 , FIG. 26 may illustrate an alternateembodiment of a splice joint. The splice joint in FIG. 26 may connecttwo pieces of different materials. The first part 2600 may contain anotch 2602 and a tab 2604. The notch 2602 may receive the tenon 2612 onpiece 2610, and the tab may be inserted into the corresponding tabbednotch 2614. This joint may be used when it is desired that the materialof part 2600 is concealed.

The following examples may illustrate a method for structuring data forsolving two-dimensional and three-dimensional design problems. Theproblem spaces may be explored manually through an intuitive graphicaluser interface (the interface may be web-based) as well as automaticallywith generative design algorithms. Problem spaces may be structured aslayered networks of sets where sets may represent design elements, suchas units, peripherals of units, other design elements like empty space(required for space planning), and groupings of design elements. Thefeatures may show various methods or ways of manipulating the differentdimensions of the units or sets. The following examples may focus onaltering just one dimension, such as the width, for the sake ofsimplicity and illustration, although it may be contemplated that theymay be applied to any other dimensions of the object, such as thelength, the height or the depth, as desired. Structuring of the problemspace in this way may allow for cohesion and consistency in modeleddesign solutions while the networks of sets are generated and edited. Asa result, functions for generating and editing the sets may be programedto be called manually by a user through a design interface orautomatically by generative design algorithms, such as a geneticalgorithm. One or more of the set division, set editing, and setgeneration features and functions described below may be used in thegeneration of a set as a set generator function. In much the same waythat a design professional may provide recommended design solutions aswell as alternatives to a client, the generative design algorithm maypresent the customer (user of the software) with suggested designs forconsideration. Because the underlying structure of the problem space maybe the same for both manual and automatic generation and editing ofdesign solutions, the client, with limited design experience with theproblem space, may be directly engaged in the creative design process.

Referring now to exemplary FIGS. 27A, 27B, and 27C, FIG. 27A mayillustrate a set and subsets as dimensional drawings and layered graphs.The dimensional drawings 2702 may show the relative dimensionalvariables of the sets, such as height and width. The layered graphdrawings 2704 may show the hierarchical data structures for each networkof sets. In this exemplary embodiment, the first set A may have two freedimensions, such as height and width. Further, there may be subsets onlayers below set A, which may share one or more dimensions inheritedfrom the parent set. They may also have one or more free dimensionswhich may be a fraction of the corresponding dimension of their sharedparent set. In an exemplary embodiment, the sum of the free dimensionsmay equal the shared parent dimensions. In the exemplary embodimentillustrated in FIG. 27A, the heights of sets B, C, and D are each afraction the height of set A, and their combined heights may equal theheight of set A. The width of sets B, C, and D may be equal to the widthof set A. FIG. 27A may illustrate two layers of ordered sets, where setsB, C, and D are subsets of set A. FIG. 27B may illustrate an alternateembodiment, where sets D and E are subsets of set A, and sets B and Care subsets of set E, which is a subset of set A. The heights of sets Band C are each a fraction the height of set E, and their combinedheights may equal the height of set E. Sets B and C may be characterizedas a third layer, since they are a subset of set E which is a subset ofset A. Exemplary FIG. 27C may illustrate a configuration with fourlayers. In this exemplary embodiment, sets F and G are subsets of set C,which is a subset of set E, which is a subset of set A. The widths ofsets F and G may be free dimensions; however, they may inherit theirheights from set C.

Referring now to exemplary FIG. 28 , FIG. 28 may illustrate sets andsubsets in three dimensions. The sets and subsets may be modeled with aheight, width, and depth. The set 2802 may contain a set A which mayhave 3 free dimensions. Set A may further include subsets B and C, asmodeled by the layered graph 2804. Three-dimensional subsets may haveone free dimension and two inherited dimensions. Sets B and C of the set2802 may share the width and depth of set A, while having a free height.In this exemplary embodiment, the combined height of subsets B and C isequal to the height of set A.

The set 2806 may contain a third layer, in which subsets D and E may besubsets of set B, as modeled by the layered graph 2808. The subsets Dand E share a height and depth with set B, and their combined width mayequal the width of set B. The set 2810 may contain a fourth layer, inwhich subsets F and G are subsets of set D, which is a subset of set B,which is a subset of set A, as modeled by the layered graph 2812.

Referring now to exemplary FIG. 29 , FIG. 29 may illustrate an exampleof how an algorithm may calculate a value range for a variable of a set.For example, the algorithm may determine a maximum and a minimum height,width, or depth of a dimension of a set. In an exemplary embodiment, thealgorithm may use the total set width 2902 to calculate a maximum subsetwidth 2904. Additionally, the algorithm may calculate a minimum subsetwidth 2906. The determination of the maximum and minimum subset widthmay allow the algorithm to determine a maximum or minimum number ofsubsets each set can hold.

Referring now to exemplary FIG. 30 , the implementation of a set editingfunction may be illustrated. In this exemplary illustration, set A mayhave three subsets, and the user may add a fourth subset. It isunderstood that in this example and all subsequent examples of setediting functions and set generating functions, an automation algorithmmay substitute for the user, where the parameters and decisions areprobabilistically or heuristically determined. The user may click on theinsertion position 3002 to select where the additional set is to beinserted. In this exemplary case, the user selected the insertionposition 3002 between sets C and D, and an additional set E was added.It may be contemplated that the user may have chosen one of any numberof possible insertion points, such as the point between sets B and C. Ifthe user attempts to insert a set in a dimension where the maximumnumber of sets has already been reached, an error message may appear toexplain to the user why the additional set may not be added. Thealgorithm may not add the additional set if the sum of the minimumwidths for sets B, C, E, and D exceeds the width of set A.

Referring now to exemplary FIG. 31 , an exemplary set editing functionmay be shown where a subset is removed from a set. The algorithm maytake the subset to remove as the input. The user may select which subsetis to be removed. In this exemplary embodiment, the user selected subsetC to be removed. As a result, the algorithm removed subset C andincreased the widths of subsets B and D so that their widths equal thewidth of the parent set A. Before removing set C, the algorithm maycheck if the maximum widths of the remaining sets B and D are equal toor greater than the width of set A. If the maximum widths of theremaining sets is less than that of the parent set, the selected subsetmay not be removed. Additionally, when a subset cannot be removed thealgorithm may display an error message to inform the user of theanomaly.

Referring now to exemplary FIG. 32 , FIG. 32 may illustrate an exampleof a set editing function where one free dimension of a subset may bechanged. The user may select a subset to change and input a new subsetdimension. In this exemplary embodiment, sets B, C, D, and E may besubsets of set A. The user may enter a new width for set B, the width ofset C may be fixed, and the widths of sets D and E may be variable. Thealgorithm may then calculate new widths for sets D and E, while changingthe width for set B corresponding to the user input. The differencebetween the old value for the width of set B and the new value for thewidth of set B may be proportionally divided between the variable sets,in this case sets D and E.

Referring now to exemplary FIG. 33 , FIG. 33 may illustrate an exemplaryset editing function where free dimensions of multiple subsets may bechanged simultaneously. The user may select a set and may choose thedimensions of the subset to alter. In this exemplary embodiment, thewidths of sets B, C and D are represented as fractions of the width ofset A, where their combined proportions equal 1.0. New width values ofany real number are either assigned to the sets or are calculated byadding these new width values to the previous width values as shown inthis example. The array of ordered values is then normalized by thealgorithm to generate values for sets B, C and D that are proportions ofset A. In this exemplary embodiment, the width of set B is decreased by0.2, the width of set C is not changed, and the width of set D isincreased by 0.4. The resultant ordered array of values for sets B, Cand D are 0.3, 0.3, and 0.6. As shown in the exemplary embodiment, thenormalized values for the array of values are 0.25 (width of set B),0.25 (width of set C), and 0.5 (width of set D). In another case, theuser may change the free dimensions of multiple subsets sequentially. Inthis exemplary embodiment, the user selected sets B and D, and thenchose to reduce the width of set B by 0.25 while increasing the width ofset D by 0.3. The algorithm may then allocate any remaining space to theunselected variable widths, in this case the width of set C was reducedby 0.05. The user may select a ratio or proportion to reduce, forexample by decreasing the width of set B by 0.25 or 25% of the totalwidth. Alternatively, the user may reduce the dimensions directly, suchas by selecting an option to reduce the width of set B by 0.25 feet.

Referring now to exemplary FIG. 34 , FIG. 34 may illustrate an exemplaryset editing function where the widths of multiple sets within a networkof sets are made equal. The user may select multiple sets, and thealgorithm may automatically set the network of sets to have equalwidths. In the exemplary embodiment illustrated in FIG. 34 , the usermay select D, E, and C, and the algorithm may allocate equal widths foreach of the selected sets.

Referring now to exemplary FIG. 35 , FIG. 35 may illustrate an exemplaryset editing function which may change the free dimension of a subsetwhile the position and width of another subset of the same set is fixed.The function may take the set to change and the new value for the set asinputs. In this exemplary embodiment, sets B, C, D, and E are subsets ofA, and the position and width of set C is fixed. When the width of set Dis changed, the width of set B may stay the same because altering thewidth of set B may change the position of set C. As a result, the widthof set E is the sole dimension which is reduced to compensate for theextension of the width of set D.

Referring now to exemplary FIG. 36 , FIG. 36 may illustrate an exemplaryset editing function which may change a non-dimensional variable of aset. A user may select a set to change, and then may select a variableto change as well as the new type or value of the variable. In thisexemplary embodiment, the type of material of set C is changed.

Referring now to exemplary FIG. 37 , FIG. 37 may illustrate an exemplaryset editing function which may replace dimensional and/ornon-dimensional parameters of a set with parameters copied from anotherset. In the exemplary embodiment illustrated in FIG. 37 , the dimensionsof set C, consisting of subsets E and F, are copied over to set D. As aresult, set D may have the same subsets as set C, and may furtherinclude the same materials, widths, and heights. The algorithm may notcopy all parameters and subsets from the reference set to the targetset. The algorithm may copy as many subsets and parameters as possible.For instance, if the width of set D is fixed, the algorithm might copysubsets and their materials and heights, but not widths.

Referring now to exemplary FIG. 38 , FIG. 38 may illustrate an exemplaryset editing function which may change or swap the positions of setswithin a network. A user may select one or more sets and select one ormore new positions for those sets. In the exemplary embodimentillustrate by FIG. 38 , the user selected sets C and D and switchedtheir positions such that set C was now in the position set D previouslyoccupied, and vice-versa.

Referring now to exemplary FIG. 39 , FIG. 39 may illustrate an exemplaryset editing function which may group neighboring sets. Multiple setswhich are near each other may be selected by a user and may be groupedto become one set which may share some dimensions. In this specificexemplary embodiment, set C contains subsets E and F, and set D containssubsets G and H. Sets F and H are selected and grouped together, suchthat they may share the same height. Further, sets E and G may beselected and grouped together such that they share the same height.

Referring now to exemplary FIG. 40 , FIG. 40 may illustrate anotherexemplary set editing function which may align the division between setsor subsets. A user may select a dividing line between two sets, and mayselect another dividing line to line it up with. In the exemplaryembodiment illustrated in FIG. 40 , the dividing line between sets D andE is selected and aligned with the dividing line between sets F and G.

Referring now to exemplary FIG. 41 , FIG. 41 may illustrate a graphoptimization function. In this example, subset D was removed from set C.As a result, set C had just one subset, set E. The graph optimizationfunction may then remove subset E since it may be the only remainingsubset of set C, and its dimensions may equal those of set C.

Referring now to exemplary FIG. 42 , FIG. 42 may illustrate an exemplaryset editing function (one point crossover set generator function of agenetic algorithm) which may generate a new set by splitting two inputsets and combining one portion of the first input set with a portion ofa second input set. The function may take one input set, a crossoverpoint from the first input set, a second input set, and a crossoverpoint from the second input set as inputs. In this specific exemplaryembodiment, the first input set (set A) may have two ordered subsets(sets B and C). Set C may have three ordered subsets D, E, and F. Thesecond input set (set G) may have two ordered subsets (sets H and I).Sets H and I may each have two ordered subsets. The first crossoverpoint may be between neighboring sets D and E. The second crossoverpoint may be between the neighboring sets J and K. The output may be anew set, a copy of set A, with ordered subsets (copies of sets B and C),where the copy of set C has two ordered subsets (copies of sets D andK).

Referring now to exemplary FIG. 43 , FIG. 43 may illustrate an exampleof a set editing function (two point crossover set generator function ofa genetic algorithm) which may generate a new set by splitting two inputsets and combining portions of the first input set with portions of asecond input set. In this exemplary embodiment, the function may takeone input set, multiple crossover points from the first input set, asecond input set, and multiple crossover points from the second inputset as inputs. In this example, the first input set (Set A) has fourordered subsets (Sets B, C, D, & E), and the second input set (Set F)has three ordered subsets (Sets G, H, & I). Crossover points for thefirst set are between B & C and Sets D & E. Crossover points for thesecond set are between Sets H & I and after Set I. The output may be anew set (a copy of Set A) with ordered subsets (copies of Sets B, I, &E). Other exemplary set generator functions with more than two crossoverpoints may be considered.

Referring now to exemplary FIG. 44 , FIG. 44 may illustrate an exemplarykitchen plan layout. The room for the kitchen design may have overalldimensions, such as a length 4402 and a width 4404 (x, y), an open side4406, three walls, and one window in one of the walls 4408. The kitchendesign may include base cabinet units 4410, wall cabinet units 4412, anappliance 4414 and a sink 4416 along the wall with the window. It mayalso include kitchen island cabinets 4418, an aisle 4420 between thekitchen wall and kitchen island, and aisles between the kitchen islandand side walls.

Referring now to exemplary FIG. 45 , FIG. 45 may illustrate an exemplarymethod for generating the kitchen plan layout design shown in FIG. 44 .The method may generate and edit a network of sets, shown here asdimensional drawings. First, the overall room may be shown 4502 as setA, where the width may be equal to the x-dimension of the space and theheight may be equal to the y-dimension of the space. Next, the space(Set A) divided into three zones 4504 (Sets B, C, & D as ordered subsetsof Set A). In a next step, the type parameter of Set B (zone along thewall with the window) may be changed 4506, such as to ‘Kitchen Wall’. Ina next exemplary step, a set, set D (zone next to the room edge open toanother space) in this case, may be divided into three zones 4508 asordered subsets (Sets E, F, & G). Further, the type parameter of Set Fmay be changed 4510, such as to ‘Kitchen Island’ in this exemplaryembodiment. In a next exemplary step, new width parameters may be set4512 for the sets. In this exemplary embodiment, the widths of sets E,F, & G were changed. Alternatively, the previous steps may be skipped byselecting a standard kitchen plan layout type from a list of standardpre-programed kitchen plan layouts.

Referring now to exemplary FIG. 46 , FIG. 46 may illustrate exemplarypre-programmed subsets. These subsets may allow for completelypre-programmed kitchen plan layout types. By using pre-programmedkitchen plan layouts or sets, the user may save time by decreasing thenumber of required steps in generating a kitchen plan layout design.Additionally, the pre-programmed sets may be examples of room designsthat may be subsets of networks of sets representing floor planconfigurations of buildings. The pre-programmed kitchen plan layouts mayhave relative and standard free dimension parameters that enableconformity with the overall room dimensions of a set.

Referring now to exemplary FIG. 47 , FIG. 47 may illustrate an exampleof a kitchen wall layout. The wall may have overall dimensions such as awidth and a height (x, z). The wall may have one window of auser-defined size. The wall may include an appliance, cabinet units,base units, a sink base cabinet unit with doors, two base cabinet unitswith doors and drawers, and a work area above the base cabinet units.

Referring now to exemplary FIGS. 48A and 48B, FIGS. 48A and 48B mayillustrate an exemplary method for manually generating the kitchen walldesign shown in FIG. 47 . FIG. 48A may illustrate the method usingdimensional drawings, while FIG. 48B may illustrate the method usinglayered graphs. In an exemplary first step, the algorithm may create anew set A with a width equal to the x dimension of the space and aheight equal to the z-dimension of the space 4802. Set A may be dividedinto ordered subsets, such as subsets B, C, and D in the exampleillustrated here. Set C may be a column with fixed position and widthparameters and may be divided into two subsets, E and F. Set E maydenote the window zone with a fixed height parameter. In a nextexemplary step, additional appliances and cabinet units may be added4804. In another exemplary step, columns may be added with wall unitsand base units 4806. These may be added to the network of sets. In anext exemplary step, wall units work areas and base units may be grouped4808. In a next exemplary step, doors, drawers, and fixed panels may beadded to the network of sets 4810. In a final exemplary step, the widthsof doors represented by sets b, c, and P may be made equal. Thealgorithm computes new width values for sets b, c, P, and K (parent setof sets b and c), so that widths of sets b, c, and P are equal, and thesum of the widths of sets P and K equal the width of their parent set,set J.

Referring now to exemplary FIG. 49 , FIG. 49 may illustrate an exemplarymethod for automatically generating a set by calling set editingfunctions. In this example, components, units, columns, and kitchenwalls may be sets with ranges of dimensional and non-dimensionalparameters particular to those set types. Components may be subsets ofunits, and units may be subsets of columns. Parameters for these setsmay be randomly selected from domains of possible values. Theprobability that any one value within a range of possible values may beselected may be weighted to increase the odds that some values may beselected over others. Optimal weights may be selected by the programmerof the algorithm, calculated from variable values entered by a user, ormay be determined using machine learning algorithms. In this exemplaryembodiment, a kitchen wall set may be generated using predeterminedoverall dimensions. The layered graphs of the kitchen wall may benormalized and optimized for efficient analysis and future set editing.Networks of sets may be automatically generated using heuristicalgorithm(s), metaheuristic algorithm(s) and/or optimizationalgorithm(s).

Referring now to exemplary FIG. 50 , FIG. 50 may illustrate an exemplarykitchen wall design systematically generated by the method described inFIG. 49 . In this example, some of the weights used in the randomselection of unit types and other parameters may be determined by userdefined values such as the overall dimensions of the wall and therequired number of appliances. Heuristics may be integrated toefficiently generate acceptable design solutions. For instance, Set G inthis example may be a required appliance, and only one appliance may beallowed. When iterating through the subsets of Set A, the probabilitythat the appliance will be added to any given subset is the index valueof the subset within the array of sets divided by the number of subsets,guaranteeing the inclusion of the appliance in the network of sets. Thealgorithm may adjust selection weights throughout the generation. Forexample, when an appliance is added to the network of sets, theprobability another appliance will be added may be adjusted to zero,guaranteeing the exclusion of solutions with multiple appliances.

Referring now to exemplary FIG. 51 , FIG. 51 may illustrate theutilization of a genetic algorithm for automatically generating andselecting set designs. Following this process, an initial population ofindividual sets may be automatically created with initial set generationfunction(s). Fitness scores for each individual set in the populationmay be calculated. A fitness score may be calculated from multiplefactors weighted by user inputs, such as design aesthetic and functionalrequirements. An example design aesthetic may be the selection of avertical appearance, resulting in networks of sets with narrow setproportions. In the example shown in FIG. 50 , a functional fitnessscore may be higher for solutions with higher calculated continuous workarea lengths. Another fitness function may be cost, when selected settypes represent physical products with variable amounts of material andconstruction complexities.

Referring now to exemplary FIG. 52 , FIG. 52 may illustrate an exampleof a population of individuals with fitness scores. After calculatingfitness scores of the population, the algorithm may decide to either endthe process and return individual(s) from the current population, orgenerate a new population. Example factors for making this decision mayinclude a limit on computing resource, a limit on number of generations,the presence of minimally viable design solution(s), or minimaldifferences in scores between current and previous populations. Togenerate new populations, the genetic algorithm may follow a processinspired by natural selection where a network of sets and parameters ofthe sets in the network may represent an individual's genotype, and thecollection of units and their parameters associated with sets within thenetwork of sets may represent the phenotype, and where new populationsof networks of sets may be generated by selecting networks of sets fromthe previous generation. Each selection is probabilistically determinedby the fitness scores of the phenotypes. The selected networks of setsand their parameters are modified with crossover and mutation operators,forming a new generation. In this example, the crossover and mutationoperators of the genetic algorithm are the set generator and set editingfunctions.

Referring now to exemplary FIGS. 53A and 53B, an implementation of a setgenerator function by a genetic algorithm may be shown. The generationof a kitchen wall set may come from one or more input sets. In thisexemplary embodiment, the input sets may be selected from a populationof sets. In this exemplary embodiment, the set generator function is asingle point crossover function, similar to the set generator functionillustrated in FIG. 42 , where the crossover point of the first inputset is between ordered sets D and E, and the crossover point of thesecond input set is between ordered sets f and g.

Referring now to exemplary FIG. 54 , FIG. 54 may illustrate an exemplaryoutput set as a mutation of an input set. The mutated version may beachieved with a set editing function selected by a genetic algorithm. Inthis example, the input set is edited by grouping the wall cabinet doorsof the input (Sets M, N, U, V, d, & e) with the set editing functionillustrated in FIG. 39 , making the widths of these doors equal with theset editing function illustrated in FIG. 34 , changing the number ofdrawers in a base cabinet (Set L) with the set editing functionillustrated in FIG. 31 , changing the widths of the doors of the sinkcabinet (Set X) with the set editing function illustrated in FIG. 33 ,and changing the type of a cabinet (Set C) from a sink cabinet (fixedpanel and two doors) to a base cabinet with one door with the setediting function illustrated in FIG. 36 .

Referring now to exemplary FIG. 55 is a method for creating and usingthe interface for finding a solution to a problem in a two-dimensionalor three-dimensional problem space structured as a network of sets. Anexemplary problem space may be the coordination and design of customcabinetry within a space, such as a kitchen. While a cabinet is athree-dimensional product, and a kitchen is a three-dimensional space,the design of an overall set of cabinets may be divided into coordinatedtwo-dimensional design problems spaces (one plan and one or moreelevations). A single cabinet, requiring the design and coordination ofperipherals such as doors and drawers, may be another example of adesign problem with a two-dimensional problem space.

After identifying a multi-dimensional design problem, a user interfacefor the problem space may be constructed as a network of sets andfunctions for generating and editing the network of sets. With theinterface, users with varying degrees of experience with the interfaceand knowledge of the problem space may decide to either manuallygenerate a problem solution with design aids provided by the interface,or instruct the software to automatically generate a solution withminimal inputs. An exemplary solution automatically generated fromminimal inputs may be a cabinet design with doors and drawers generatedfrom user inputs, such as size and volume or other dimensional as wellas non-dimensional requirements. Software may automatically determinemore detailed design requirements from minimal inputs provided by theuser with a question-air form or verbal instructions. Exemplary verbalinstructions may be, “I need a cabinet to hold 3 large pots, 10 smallplates, and knives” or “I want a kitchen with horizontal lines.” Usingnatural language processing algorithms along with heuristics and/ormachine learning algorithms, the software may automatically determine orapproximate unit proportions as well as volumetric and area requirementsfrom these inputs, and use these requirements as fitness criteria inautomatically generating an overall kitchen and/or cabinet designsolution.

If the user is not satisfied with the solution, the user may decide toeither manually edit the solution with design aids provided by theinterface, or instruct the software to automatically edit the solutionwith additional inputs. Machine learning algorithms (such as objectrecognition algorithms) may be trained to recognize overall kitchenstyles and aid in the generation of solutions for certain types ofquantitative as well as qualitative inputs. For instance a user mayinstruct the software to automatically generate a kitchen design thatfits their quantitative requirements in addition to having a qualitativeappearance similar to another kitchen or other kitchens.

Other exemplary interfaces with the previous mentioned features fortwo-dimensional design problem spaces may include virtual and physicalmedia with organized design elements, such as promotional flyers,stationary, and webpage layouts. These exemplary interfaces are moredesirable than current technologies, where users are only able to selectfrom a curated set of standard templates.

An exemplary three-dimensional design problem is a whole building designwith multiple levels that require design coordination between levels.The problem space for this design problem may be constructed as athree-dimensional network of sets. In the automatic generation of awhole building design, the software may perform whole building analysisin determining fitness. Exemplary analyses of a building include abuilding's relative size and position to other site elements (roads,other buildings, shading element such trees, and views), life safetyanalysis, code compliance, and energy analysis.

The foregoing description and accompanying figures illustrate theprinciples, preferred embodiments and modes of operation of theinvention. However, the invention should not be construed as beinglimited to the particular embodiments discussed above. Additionalvariations of the embodiments discussed above will be appreciated bythose skilled in the art (for example, features associated with certainconfigurations of the invention may instead be associated with any otherconfigurations of the invention, as desired).

Therefore, the above-described embodiments should be regarded asillustrative rather than restrictive. Accordingly, it should beappreciated that variations to those embodiments can be made by thoseskilled in the art without departing from the scope of the invention asdefined by the following claims.

What is claimed is:
 1. A method for constructing a unit, comprising:providing, to a user, a user interface comprising a design interface;receiving, from the design interface, a plurality of design parametersfor the unit, the plurality of unit parameters comprising at least twoof the set of: a type of the unit, a length of the unit, a height of theunit, a width of the unit, a depth of the unit, a number of doors of theunit, a number of other peripherals of the unit, and a number ofadjacencies of the unit; automatically constructing, from the specifiedplurality of parameters, a virtual illustration of the unit meeting thespecified plurality of parameters; computing, from the plurality of unitparameters, project data associated with a plurality of parts forconstructing the unit; saving, in a digital account, at least two in theset: the plurality of unit parameters, the project data, and usermetadata; generating and sending, from the user interface, a supplierorder comprising at least one of the plurality of unit parameters andthe project data; generating, from the project data, manufacturing data,wherein the manufacturing data comprises a set of instructions for aprogrammable manufacturing machine associated with the plurality ofparts, a material list, and unit assembly data; providing a material onthe material list to a programmable manufacturing machine; and executingthe set of instructions to generate the plurality of parts from thematerial, wherein the unit is modeled as a set in a network of setscomprising at least one parent set and a plurality of child sets, the atleast one first parent set corresponds to an overall space, each parentset has at least two corresponding child sets, and each child set hasone corresponding parent set.
 2. The method of claim 1, wherein thedesign interface is a Web-based interface.
 3. The method of claim 1,wherein the step of providing the material on the material list to aprogrammable manufacturing machine further comprises: generating amaterial order based on the material list and the set instructions; andproviding the material order to a material supplier.
 4. The method ofclaim 1, further comprising: assembling the plurality of parts based onthe unit assembly data; and supplying the unit to the user.
 5. Themethod of claim 1, further comprising: packaging the plurality of parts;automatically generating labels for the plurality of parts; andsupplying the plurality of parts to one of a manufacturer and the user.6. The method of claim 1, wherein the unit is a plurality of units thatare affixed to one another.
 7. The method of claim 4, wherein executingthe set of instructions further comprises: shaping the edges of theparts to form interlocking joints, and assembling the plurality of partsfurther comprises: interlocking edges of the plurality of parts.
 8. Themethod of claim 7 wherein the interlocking joints comprise at least oneof the set of: hammer-headed tenon and mortise joints, splice joints,and mortise and tenon joints.
 9. The method of claim 1, wherein eachparent set has a plurality of free dimensions, each child set has onefree dimension and at least one inherited dimension, wherein the atleast one inherited dimension is inherited from a parent setcorresponding to the child set.
 10. The method of claim 1, wherein eachparent set of the plurality of parent sets has a first dimensionalmeasurement in a first dimension, a plurality of child sets associatedtherewith, the child sets having a plurality of second dimensionalmeasurements in the first dimension, wherein a sum of the plurality ofsecond dimensional measurements is the first dimensional measurement.11. The method of claim 1, further comprising: automatically generatinga space design for the overall space, the space design made up of aplurality of units, each unit of the plurality of units defined by arespective child set.
 12. The method of claim 11, wherein the step ofautomatically generating the space design further comprises: identifyingtwo or more child sets; assigning at least one weight to the two or morechild sets; and generating a free dimension, an inherited dimension, anda position for each of the two or more child sets based on the at leastone weight.
 13. The method of claim 1, further comprising: constructinga space design for the overall space; receiving instructions to edit thespace design; receiving an acceptance or a denial of the space design;initiating a set editing function when the denial is received, whereinthe set editing function is iterative, and any iteration of the setediting function is either received from the user or automaticallygenerated, wherein the set editing function is not initiated after theacceptance is received.
 14. The method of claim 11, wherein the step ofautomatically generating the space design comprises the use of at leastone of a heuristic, metaheuristic, and optimization algorithm.
 15. Themethod of claim 11, wherein the step of automatically generating thespace design further comprises: randomly determining a number ofdivisions based on a minimum division size and a maximum division size;separating each set of the plurality of child sets into a plurality ofdivisions based on the number of divisions, each division having a sizebetween the minimum division size and the maximum division size.
 16. Themethod of claim 1, wherein the unit assembly data comprise machineinstructions and information for identifying parts.
 17. The method ofclaim 1, further comprising: computing joint data associated withconnections for joining parts, wherein the joint data depend on at leastone of the length of the unit, the height of the unit, the width of theunit, and the depth of the unit.